HIGHWAY ENGINEERING

5-3 AGGREGATE FOR PORTLAND CEMENT CONCRETE PAVEMENT 5-4 MINERAL FILLER 5-5 BITUMINOUS MATERIALS 5-6 BITUMINOUS BINDERS

5-3 AGGREGATE FOR PORTLAND CEMENT CONCRETE PAVEMENT

In order to obtain high quality concrete, road agencies have imposed almost without exception that all aggregates shall pass appropriate tests for strength, soundness, wear or the combination of these three. 1. The presence of organic impurities in the aggregates intended for concreting road pavement may cause slow or non-hardening of the concrete. Under ASSHTO T-21 standard test, the aggregate is treated with a mixture of sodium hydrochloride solution, and when the aggregate turns dark, organic materials are said to be present in the aggregate. The strength of fine aggregate is measured by the compression tests of sand-cement mortar. Soundness of fine aggregate is measured by the resistance to deterioration under the action of Sodium or Magnesium Sulfate. The sodium sulfate test is five cycles. The maximum loss under ASSHTO specification is 10%. For Coarse aggregate the requirement consists of crushed stone, gravel, blast furnace, slag or approved inert materials of similar characteristics or combination thereof having hard, strong durable pieces free from adherent coatings.

2. 3.

4.

TABLE 5-2 MAXIMUM AMOUNT OF DELETERIOUS MATERIALS PERMITTED IN COARSE AGGREGATE FOR CONCRETE AASHTO M-80 Materials Chert (2.40 specific gravity) Coal and Lignite Clay Lumps Maximum AllowablePercent by Weight

Pavements
3.00% 0.5 3

Bridge Deck
3.00% 0.5 2

Material Passing No.200 Sieve

Sodium Sulfate Soundness Magnesium Sulfate

1
12 18

1
12 18

The Department of Public Works and Highways Standard Specifications classify aggregate under item 703 and specifically provides that: 1. Aggregate shall consist of hard, durable particles or fragments of crushed stone, crush slug or crushed natural gravel. Material that breaks up when alternatively wetted and dried shall be discarded.

CHERT

COAL

LIGNITE

Aggregates soundness test before

Aggregates soundness test after

TABLE 5-3 SELECTED GRADING OF COARSE AGGREGATE FOR CONCRETE Size + Range in size Number 1-1/2 " to No. 4 3/4 " to No. 4 1 " to No. 4 1-1/2 " to No. 4 2 " to No. 4 1-1/4 " - 3/4 " 2-1 Inch 7 67 57 467 357 4 3 2-1/2 100 100 2 100 95-100 100 90-100 1-1/2 100 95-100 90-100 35-70 1 100 90-100 35-70 20-55 0-15 3/4 100 90-100 35-70 0-15 1/2 90-100 25-60 10-30 0-5 3/8 40-70 20-55 10-30 0-5 No. 4 0-15# 0-10# 0-10# 0-5 0-5 Percentage by Weight Passing L aboratory Sieves Having Square Openings

AASHTO Designation M-80

+ Based on Standard Sizes of Coarse for Highway Construction AASHTO Designation M-43 # Note more than 5% shall pass a No. 8 sieve

2. Coarse aggregates is the material retained on the 2.00 mm (No.10) sieve and shall have a percentage of water not more than 50 for sub-base and not more than 45 for base and surface courses as determined by ASSHTO designation test T-96.

3. Fine aggregate is the material passing the No. 10 sieve (2.00 mm) consisting of natural, crushed sand, and fine mineral particles. The fraction passing the 0.075 mm (No. 200) sieve should not be greater than 0.66 (2/3) of the fraction passing the 0.425 mm (No. 40) sieve.
4. For Base coarse, the fraction passing the 0.425 mm (No.40) sieve shall have a liquid limit of not more than 25 and a Plastic Index (PI) not greater than 35, and Plastic Index not greater than 12. 5. For Surface coarse, the fraction passing the 0.425 mm (No.40) sieve shall have a liquid limit of not more than 35 and Plasticity Index not less than 4 nor exceed 9.

Coarse aggregates

Fine aggregates

Limerock base course

5-4 MINERAL FILLER

The strength of road pavement will increased in dust additives which dense the graded mixture is added. It is called mineral filler that reduces the void contents in the mixture, this dust additive is not the ordinary dust that is being found in our floor or tables. Dust additive is classified into:

1. Finely Powdered Limestone 2. Slag 3. Hydrated Lime 4. Portland Cement 5. Trap Rock Dust 6. Fly Ash
The DPWH Standard Specifications relative to mineral filler states that: Mineral filler shall consist of finely divided mineral matter such as rock dust, slag dust, hydrated lime, hydraulic cement, fly ash or other suitable mineral matter. It shall be free from organic impurities and at the time of use shall be sufficiently dry to flow freely and shall be essentially free from agglomerations AASHTO M-17 provides that: Percentage passing by weight shall be as follows: No. 30(0.66 mm) sieve No. 50(0.30 mm) sieve No. 200(0.075 mm) sieve 50 95-100 70-100

AASHTO further stipulates that all minerals other than hydrated lime or Portland cement, the Plastic Index (PI) value shall be 4 or less.

Finely powdered limestone

Slag

Hydrated lime

Mineral filler

Portland cement

Trap rock dust

Fly ash

5-5 BITUMINOUS MATERIALS

Bituminous material or Asphalt in short, is a viscous liquid used as binders for aggregates in road construction. At normal temperature, asphalt is either slightly thicker than water or hard but brittle material that breaks a hammer blow when cold. 1. Bituminous material is in liquid form when mixed or combined with aggregates. This liquid form maybe produced either by heating the hard asphalt, by dissolving in solvent or by emulsifying in water however, there are bituminous liquid materials available and ready for use. 2. The action of asphalt binder depends on its type and the aggregate it is combined with. The purpose of the asphalt binder is to resist the abrasive force true heavy traffic. 3. If road pavement is the open type, consisting entirely of coarse particles and asphalt, heavy binder is needed requiring more asphalts. On the other hand, if the aggregates in the pavement contains fine particles, cohesion will be developed by surface tension in the thin asphalt film surrounding the fine particles. Hence, less viscous asphalt is required.

TABLE 5-4 SUGGESTED SPRAYING AND MIXING TEMP. (C) FOR BITUMINOUS MATERIALS AND ROAD TARS*+ Pugmill Temperature + Spraying Temperature** Type and Grade of Asphalt Dense Grade Mixes Asphalt Cement AC-2.5 AC-5 AC-10 AC-20 AC-40 AR-1000 AR--2000 AR-4000 AR-8000 AR-16000 200-300 pen 120-150 85-100 60-70 40-50 Cutback Asphalt (RC, SC) 30 (MC Only) MC. 70 250 600 3000 Emulsified Asphalt RS-1, CRS-1 RS-2, CRS-2 MS-1, MS-2, CMS-2 MS-2h, CMS-2h SS-1, CSS-1 SS-1h, CSS-1h Road Tars RT1-2-3 RT5-6 RT7-8-9 RT1-0-11-12 65-105 80-120 15-55 27-65 65-105 80-120 15-55 27-65 65-105 80-120 10-70$ 10-70$ 10-70$ 10-70$ 20-70 20-70 20-70 20-70 20-60 50-80 50-80ii 75-100ii 80-150ii 20+ 40+ 55+ 30+ 50+ 75+ 95+ 110+ 115-140 120-145 120-155 130-165 130-170 105-135 135-165 135-165 135-165 150-175 115-150 120-155 120-165 130-170 130-175 80-120 80-120 80-120 80-120 80-120 80-120 80-120 80-120 80-120 80-120 80-120 80-120 80-120 80-120 80-120 130+ 130+ 140+ 145+ 150+ 130+ 140+ 140+ 145+ 150+ 135+ 140+ 145+ 145+ Open Grade Mixes Road Mixes Surface Temp.

+ F=9/5C+32 $ Temp. of the emulsified asphalt in the pugmill mixture Ii Rapid curing RC grades are not recommended for hot pugmill mixing ** Max. Temp. asphalt cement and cutback asphalt shall be below that at which fogging occurs.

5-6 BITUMINOUS BINDERS

Asphalt cement is used as binder for almost all high types of bituminous pavement. Asphalt cement is a semi solid hydrocarbon retained after the fuel and the lubricating oils are removed from the petroleum. The 60-70 penetrations is the hardest type . penetration refers to the consistencies of asphalt cement as described under AASHTO-T49. it is the distance that the standard needle penetrates a sample under known conditions of loading time and temperature. Recently, the procedure used in grading asphalt cement is the Viscosity Test rather then the Penetration Test. Cutback or Liquid Asphalt 1. Liquid asphalt is a petroleum product consisting of asphalt cement with a liquid distillate (diesel, kerosene or gasoline). The less viscous asphalt contains diluents as little as 15%. 2. The use of cutback is being frowned for two reasons: a. It is a usable fuel. b. It is an air pollutant. 3. Cutback or liquid asphalt is classified into: a. Slow curing (SC) road soil. b. Medium curing (MC) cutback asphalt. c. Rapid curing (RC) cutback asphalt.

Cutback or Liquid Asphalt

Emulsified Asphalt
Emulsified asphalt is a kind of mixture wherein the minute globules of asphalt disperses in water. Asphalt content ranges from 55% - 70% by weight. Emulsion could be applied or mixed at normal temperature, because when the water content evaporates, the asphalt remains. It has the following characteristics. 1. Emulsified asphalt is excellent wit wet aggregate because the water medium carries the asphalt into a superior contact with the particle surfaces. 2. Emulsified asphalt is an alternate to cutback asphalt for energy and environmental objectives. It is an effective material in coating electropositive aggregate such as limestone but tend to strip from aggregates with high content of silica for having strong electronegative surface charges. 3. The Cationic Emulsion is very effective on high siliceous aggregates but may strip from high alkaline that carry strong positive surface changes. 4. Rejuvenating Agent is an emulsified petroleum resin sprayed over the surface of an old asphalt road that changes to asphaltenes causing the binder to harden and cracks. The rejuvenating agent sprayed over the pavement and softening the binder. Too much application however, produces a slick pavement surface.

Cationic Emulsion

Emulsified asphalt

Oxidized Asphalt and Road Tar

Oxidized asphalt is suitable only for roofing and similar application. Highway used of oxidized asphalt is limited to water proofing of structures and filling joints of concrete pavement. Road tar is by-product of the distillation process of coal. Tars are produced from gashouse coal tar, cook oven tars and water gas tar. The AASHTO classification of coal tars includes RT-1 to RT-12 and RTCB-6. RT-1 is suitable for application as tack of Prime Coat at normal temperature. The DPWH Specifications Classify Bituminous Tack Under Item 302 which provides that: 1. Bituminous materials shall be either Rapid Curing Cut Back or Emulsified asphalt. 2. Tack Coat shall be applied only to dry surfaces or slightly moist. No tack coat shall be applied when the weather is either foggy or rainy. 3. Immediately prior to the application of Tack Coat, the road surfaces lightly sprayed with water, but not to be saturated. 4. The rate of application of either the Rapid Curing, Cut Back or Emulsified asphalt is within the range of 0.2 to 0.7 liter per square meter. Any excess of this specified quantity should be blotted by sand or removed. 5. Tack Coat shall be sprayed not only as far I advance on the surface course as will permit I to dry and tacky condition. Traffic shall be kept off the Tack Coat until after fully dried.

Oxidized asphalt

Tack Coat

Bitumen-Rubber mixture
The bitumen rubber mixture for road pavement was experimented in Holland in the year 1929. It was adopted in the United States in 1947 and later, in European countries. The assessments of the road states: 1. Very little improvement gained as far as coefficient of friction on newly laid pavement but expect higher advantages after six months. The analysis of the Bureau of Public Roads states that: An appraisal of the real economic value of the addition of rubber to asphalt must wait on further observation of the behavior of experimental pavements under the influence of age, weather and traffic. 2. According to the report, powdered rubber foams added to bitumen has improved the stability of some but not all.

Epoxy Resin as Binders

Epoxy binders are produced in a clear, dark, rigid and flexible form for application to either concrete or asphalt pavement. Hardening can be attained by mixing the resin and the catalyst hardener prior to application. The result is called thermosetting. Meaning, it will not soften under the influence of heat or the action of solvent like water or petroleum products. The high cost of resin has restricted its use to bridge surfacing and other special non-skid seal coating surface only.

Test for Bituminous Binders

1. a. b. c. d. e. f. Test of consistency is subdivided into: Kinematics Viscosity test SAYBOLT-FURAL TEST Engler specific gravity test The float test Penetration test Softening point test AASHTO T-202 AASHTO T-72 AASHTO T-54 AASHTO T-50 AASHTO T-49 AASHTO T-53

2. Test for durability AASHTO T-52 3. Test for solubility AASHTO T-44 4. Distillation test AASHTO T-78 5. Thin film oven test AASHTO-179 6. Flashpoint AASHTO T-48%79 7. Test for homogeneity of petroleum asphalt AASHTO T-102 8. Special test for emulsion asphalt AASHTO T-59 a. b. c. Test for demulsibility Test for settlement Sieve test d. Cement mixing test e. Particle charge and PH Test f. Miscibility and freezing test

Kinematics Viscosity tester

Engler specific gravity tester

The float tester

Penetration tester

Softening point tester

Distillation tester

Thin film oven test

Flashpoint tester

Sieve tester

Cement mixing tester

Particle charge and PH Tester